STRATEGIC STORAGE OF CRUDE

OIL AT VISAKHAPATNAM

C-2.1, Annexure 1. CONTROL PROGRAMME

BY CHECKED APPROVED
CASO UH GERI

ISSUED FOR BID

Stockholm 24 August 2007

Project No. 2158005

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SWECO INTERNATIONAL
Gjörwellsgatan 22
P.O. Box 34044
SE- 100 2 6 Stockholm, Sweden
Telephone +46 8 695 65 00 Project 2158005;
Fax +46 8 695 65 10
 C-2.1, Annexure 1. CONTROL PROGRAMME

Table of contents

1 General 1

2 Testing of shotcrete 3
2.1 General 3
2.2 Suitability testing 3
2.3 Continuous testing 4

3 Testing of rock bolts 6

3.1 General 6
3.2 Pull-out tests 6
3.3 Control of grout 6

4 Control of Rock Mass grouting 8

4.1 General 8
4.2 Control 8
4.3 Equipment 8
4.4 Suitability testing of Grout Mixes 8
4.5 Continuous testing 9
4.6 Documentation 9

5 Monitoring of borehole deviation 11

5.1 General 11
5.2 Water curtain boreholes 11
5.3 Injection boreholes 11
5.4 Documentation 11

6 Control of tunnel contour 13

6.1 General 13
6.2 Control of section 13

7 Geological documentation 14

8 Control of stability 15
8.1 General 15

9 Ground water monitoring 16

9.1 In leaking of Ground Water 16
9.2 Ground Water Level 16
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24 August 2007 ISSUED FOR BID Project 2158005;

Strategic Storage of Crude Oil at
Visakhapatnam
 1 General
This Control Programme applies to all underground rock works.

The Contractor shall in his control plans include testing, inspection

and monitoring in order to fulfil the requirements in this document.

The control plans shall for all testing, inspection and monitoring
activities describe the control works according to the following
contents:

1. Purpose

2. Execution

3. Amount of test

4. Requirements

5. Documentation and reporting

6. Actions when the requirements are not met

Underground works will not be allowed to start until the quality plan
and control plans have been reviewed by the Owner. This review
does not free the Contractor of the responsibility to revise the control
plans later, should this be considered necessary. Revisions shall also
be reviewed by the Owner before they are implemented.

In general, all material delivered to site shall be controlled with

respect to requirements on storage and the type and marking on each
shipment.

Tests are divided into suitability tests and continuous tests. Suitability
tests shall be executed, reported and approved by the Owner before
the actual work can start.

Results from tests shall without delay be presented to the Owner’s

Engineer. The Contractor is responsible to file all protocols in an
archive on site.
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C-2.1-Annexure 1. CONTROL PROGRAMME

24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 1 (16)
Visakhapatnam Project 2158005;
 If the requirements are not met, the Contractor shall immediately
notify the Owners Engineer together with proposed corrective actions,
to be approved by the Owner’s Engineer. The Contractor shall
investigate the cause for the non-approved results.

If not stated otherwise, all testing and control shall be performed by

the Contractor with the equipment that will be used during
construction. The Contractor shall document and file the tests and
their results.

The equipment used for testing and control shall be checked 1

time/month.
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24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 2 (16)
Visakhapatnam Project 2158005;
 2 Testing of shotcrete

2.1 General
The purpose of the suitability testing is to define the concrete recipe,
type and amount of fibres, for fibre reinforced shotcrete, and
necessary time for hardening.

2.2 Suitability testing

Applying shotcrete for testing shall be with the same personnel and
equipment as for the production. During the spraying operation, the
ability of the fresh shotcrete to be sprayed and pumped and the
amount of spill shall be checked.

2.2.1 Uniaxial compressive strength

Requirement on uniaxial compressive strength is strength class
C32/40 according to EN 206-1.

The test shall consist of 2 series with 3 tests in each series where all
tests shall fulfil the requirements.

2.2.2 Density
Density during the suitability tests shall be determined according to
EN 12390-7/AC:2004.

2.2.3 Bond strength

The bond strength between the shotcrete and rock mass shall be
minimum 0.5MPa and between layers of shotcrete 1.0 MPa according
to EN 14488-4.

The tests of bond strength between shotcrete and rock mass shall be
in rock with Q=4 or better. The locations shall be agreed upon
between the Contractor and Owner.
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The amount of tests shall be two series of three tests each for bond
strength between rock and shotcrete and two series of three tests
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 each for bond strength between shotcrete layers. For each series, the
average value shall fulfil the requirement.

2.2.4 Flexural strength

This applies for fibre reinforced shotcrete only.

The requirements for flexural strength shall be class D2S3 according

to EN 14487-1:2005.

The test consist of 2 series with 3 test beams in each series.

2.3 Continuous testing

Continuous testing is performed as the various works proceeds. The
required amount of testing shall be of finished support.

2.3.1 Uniaxial compressive strength

Requirement on uniaxial compressive strength is strength class
C32/40 according to EN 206-1.

One test for each 1000 m 2 shall be performed.

2.3.2 Density
Density shall be determined according to EN 12 390-7/AC:2004.

The test shall consist of one test for each 1000 m 2.

The density determined during continuous testing may not differ more
than 130 kg/m 3 from the density determined during the suitability
tests.

2.3.3 Bond strength

The bond strength between the shotcrete and rock mass in areas
where this bond is required shall be minimum 0.5 MPa according to
EN 14488-4. Such areas shall be agreed upon between the
Contractor and the Owner.

The bond strength between layers of shotcrete shall be minimum 1.0

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MPa according to EN 14488-4.

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24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 4 (16)
Visakhapatnam Project 2158005;
 The test shall consist of one serie of 3 tests for each 1000 m 2.

2.3.4 Flexural strength

This applies for fibre reinforced shotcrete only.

The requirements for flexural strength shall be class D2S2 according

to EN 14487-1:2005.

The test consists of one series for each 2000 m 2 of shotcrete. Each
serie consist of 3 test beams.

2.3.5 Fibre content

The fibre content shall be performed by inspecting the beams for the
test of flexural test. The fibre distribution in the shotcrete shall be
inspected and the requirement is that the fibres shall be well
distributed in the shotcrete.
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C-2.1-Annexure 1. CONTROL PROGRAMME

24 August 2007 ISSUED FOR BID

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Visakhapatnam Project 2158005;
 3 Testing of rock bolts
This section applies to all rock bolts in the permanent support.

3.1 General
The purpose with this test is to verify the quality of the grouted rock
bolt through inspection of the workmanship and testing grouted bolts.

3.2 Pull-out tests

3.2.1 Suitability testing

Suitability testing shall be performed on 6 bolts with a length of 3 m.
The pull-out force shall conform to 90% of the yield strength of the
bolts. The test shall be performed 10 days after the bolts were
installed.

3.2.2 Continuous testing

Continuous testing shall be performed as requested by the Owner.
This testing will consist of testing 10 bolts of each length.

3.3 Control of grout

The control of grout and installation of bolts is performed by installing
bolts in vertical pipes of Plexiglas. The pipes shall have the same
diameter as the boreholes and be mounted vertically with a length of
3 m. The rock bolt to be installed shall have a length of 3 m.

The Owner shall be present during the test.

3.3.1 Requirements
Grout: The water/cement-ratio shall be not more than 0.30. This shall
be tested with mud-balance.

Installation: The Plexiglas pipe shall be completely filled with grout.

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The bolt is inserted vertically in the pipe and shall remain in the pipe
without support. The bolt shall be completely surrounded by grout
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 with no visible air-pockets. The bolt shall be equipped with
centralisers.

3.3.2 Suitability testing

During suitability testing, 5 such installations shall be performed.

3.3.3 Continuous testing

The Owners Engineer shall determine when this test shall be
repeated. A number of 20 tests, each consisting of 5 installations, will
be performed.
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C-2.1-Annexure 1. CONTROL PROGRAMME

24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 7 (16)
Visakhapatnam Project 2158005;
 4 Control of Rock Mass grouting

4.1 General
The purpose of the control is to secure that the injection grout will
have the required properties to give the expected results.

Control of deviation of boreholes for injection and other boreholes are

given in section 5.

All tests shall be performed at temperatures similar to what prevails in

the rock mass and with the equipment that will be used during
production.

4.2 Control
Before the tests starts the Owner shall approve the types of injection
grouts specified by the Contractor and method statements for
injection works.

Filter stability is determined according to SS-EN 14497:2004/AC 2006

with sieve size 125 µm. This applies to injection cement only.

Water separation is determined according to SS-EN 445.

Density is determined with the mud-balance method.

4.3 Equipment
At site the Contractor shall keep the following test equipment:

• Mud-balance
• Marsh cone

4.4 Suitability testing of Grout Mixes

Suitability testing shall be performed on three separate mixes on each
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of the grout types A and B.

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Visakhapatnam Project 2158005;
 The grouts shall fulfil the requirements on various properties
according to the technical specification.

Requirements on density and Marsh Cone Time shall be determined

from the suitability tests.

No injection works shall start until the requirements for suitability tests
have been proven and approved by the Owner.

4.5 Continuous testing

The injection works shall be continuously monitored with regards to
the following parameters:

• Injected volume in each borehole

• Injection pressure in each borehole
• Injection flow in each borehole

The Owner shall after each injection receive a documentation of the

parameters above together with information on time, date, borehole
id, location, length and diameter.

For each injection shift, two test series shall be performed consisting
of the following tests:

• Water separation
• Filter stability
• Density
• Hardening

Hardening is controlled in the following manner: A cup, approximately

3 dl, is filled with grout. After 4 hours the cup is turned up-side down
and all grout shall remain in the cup.

All types of injection grouts (A and B) used during the shift shall be
tested.

4.6 Documentation
Documentation from the injection works above shall include the
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following:

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Visakhapatnam Project 2158005;
 • Date
• Borehole id
• Location
• Length
• Diameter
• Other important information such as connections with other
boreholes, grout leakage to the rock wall or around the packer etc.

Documentation on the tests above shall include:

• Date
• Results
• Grout mix
• Time when mixing starts
• Time for the tests
• Responsible person for the mixing and testing
• Information on the boreholes for which the tests apply
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Visakhapatnam Project 2158005;
 5 Monitoring of borehole deviation

5.1 General
The instrument shall be capable of measuring the deviation in both
vertical and horizontal direction along the entire borehole.

The start of the borehole and each measured point shall be presented
in x-, y- and z-coordinates.

The error in determining the deviation from the theoretical location of

the borehole shall be < 0.5 % along the entire borehole.

5.2 Water curtain boreholes

Initially, the first 20 boreholes in the water curtain shall be monitored
and evaluated immediately after the drilling operation. This suitability
test continue until 20 consecutive boreholes fulfil the requirements.

After the suitability test is approved, monitoring shall be performed in

every 5 borehole or when a new drill rig is taken in operation or if a
change in the geology may indicate that the drilling could be affected.

5.3 Injection boreholes

Initially, all boreholes in the first four injection screens or groups of
boreholes shall be monitored. If the deviation does not fulfil the
requirements, the monitoring continues until at least 20 consecutive
boreholes are approved.

After the suitability test is approved, monitoring shall be performed in

every 5 borehole or when a new drill rig is taken in operation or if a
change in the geology may indicate that the drilling could be affected.

5.4 Documentation
The documentation shall comprise the following:
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• Date
• Responsible person for the measurement

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Strategic Storage of Crude Oil at 11 (16)
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 • Location of borehole
• Type of borehole
• Requirement on deviation
• Borehole length and diameter
• Method of measurement
• Results in x-, y- and z-coordinates and on drawings (plan and
profile)
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24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 12 (16)
Visakhapatnam Project 2158005;
 6 Control of tunnel contour

6.1 General
The purpose of the control is to verify that the excavated contour and
the permanently supported sections fulfil the requirements given on
drawings.

6.2 Control of section

The monitoring shall be performed in sections with the following
distances between measuring points:

• In access tunnels, not included in the storage volume, and water

curtain tunnels, the distance between sections shall be not more
than 5 m and 1 m between points within each section.

• In caverns and tunnels included in the storage volume and in the

shafts, the distance between all points shall be not more than 1 m.

• In location for barriers, the distance between all points shall be not
more than 0.5 m. This area shall include 3 m on either side of the
planned location of the barrier.

All excavated volumes shall be monitored.

The excavated volume shall be continuously monitored, presented

and approved before the permanent support of shotcrete is applied.

After the permanent support is applied, the resulting contour shall be

monitored and presented.
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C-2.1-Annexure 1. CONTROL PROGRAMME

24 August 2007 ISSUED FOR BID

Strategic Storage of Crude Oil at 13 (16)
Visakhapatnam Project 2158005;
 7 Geological documentation
Requirements on geological mapping are given in the technical
specifications, section 8.
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Visakhapatnam Project 2158005;
 8 Control of stability

8.1 General
Control of stability shall be performed through monitoring the
deformations of tunnel sections with various instruments.

The Contractor shall have and maintain a system for measurement

with an optical system with survey equipment with capacity to monitor
displacements in the order of 0.5 mm. As a minimum, 1000 optical
targets shall be installed in the Caverns.

In addition to this, the Contractor shall be capable to install

extensometers as requested. A number of 20 extensometers with
lengths up to 15 m may be necessary to install depending on the
actual conditions.

The contractor shall present a detailed monitoring programme to be

used during construction depending on the actual rock mass
conditions.

Monitoring shall start immediately and be performed daily for 15 days

after excavation. After that, weekly readings shall be performed until
the end of the construction period, provided that movements have
levelled of. In the case of continuous movements, daily readings shall
continue.

The Contractor shall engage a specialist company to perform,

evaluate and report all monitoring.

Monitoring results including evaluation and conclusions shall be

presented on a weekly basis to the Owner.
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Strategic Storage of Crude Oil at 15 (16)
Visakhapatnam Project 2158005;
 9 Ground water monitoring

9.1 In leaking of Ground Water

Control of the amount of groundwater leaking into the underground
spaces shall be performed by the Contractor.

The measurements shall be performed by monitoring the water

flowing across temporary and permanent monitoring dams at various
places in the tunnels and caverns.

The exact location of the dams will be determined in the detailed

design.

It shall be expected that 20 such dams shall be constructed in the

underground tunnels and caverns.

The measurements at the dams shall be performed by closing of a

portion of the underground spaces during a few days and measure
the stable inflow. It shall be expected that during 4 times/year all such
dams can be monitored. At the time for monitoring, no activity
involving water in the tunnel system will be allowed for 72 hours. The
Contractor shall plan for this in his time schedule.

The results shall be presented and actions to reduce the inflow shall
be taken, if this is considered necessary.

9.2 Ground Water Level

Ground water levels shall be monitored in monitoring wells from the
ground level. The monitoring shall be performed by means of data
loggers installed in the monitoring wells, allowing hourly readings
from start of construction until the end of the construction period.

Data from the loggers shall be collected once a week and presented
to the Owner as level vs time in graphs
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Strategic Storage of Crude Oil at 16 (16)
Visakhapatnam Project 2158005;